Cement Mortar Body

Abstract

The invention relates to a cement mortar body ( 2 ) made up of an aggregate ( 4 ) with silica content of around 99.5% which is formed by particles with a rounded surface and particle size between 0.1 and 1 mm The existing interstices of the body are filled with an ettringite binder ( 6 ) derived from hydrating cement particles ( 5 ) with particle size of around 5 microns, and with the actual cement particles ( 5 ), perfectly hydrated. The body ( 2 ) can include microparticles ( 7 ) and colloidal materials in the interstices formed between the particles of aggregate ( 4 ), the ettringite binder ( 6 ) and the cement particles ( 5 ). The interstices created between the particles of aggregate ( 4 ), the cement particles ( 5 ) with ettringite binder ( 6 ), the microparticles ( 7 ) and the colloidal materials can include nanoparticles ( 8 ). The invention also relates to a method for manufacturing said mortar body.

1 . A cement mortar body, characterized in that it is constituted by an aggregate ( 4 ) having a silica content of around 99.5% that is formed by rounded surface particles with a particle size of between 0.1 and 1 mm, the interstices existing in the grouping of the particles themselves being occupied by an ettringite binder ( 6 ) derived from the hydration of cement particles ( 5 ) of a particle size of around  5  microns and by the perfectly hydrated cement particles ( 5 ) themselves. 
     
     
         2 . The cement mortar body of  claim 1 , characterized in that said body may incorporate in the possible interstices formed between said aggregate particles ( 4 ), said ettringite binder ( 6 ) and said cement particles ( 5 ), microparticles ( 7 ) of around one micron and colloidal materials, and, finally, nanoparticles ( 8 ) in the interstices formed between said aggregate particles ( 4 ), said cement particles ( 5 ) with said ettringite binder ( 6 ), said microparticles ( 7 ) said and colloidal materials. 
     
     
         3 . The cement mortar body of  claim 1 , characterized in that the compressive strength of the mortar has the values indicated hereinafter: around 350 kg/cm2 at 8 hours; around 500 kg/cm2 at 24 hours; around 575 kg/cm2 at 48 hours; around 750 kg/cm2 at 7 days and around 1,000 kg/cm2 at 28 days. 
     
     
         4 . The cement mortar body of  claim 1 , characterized in that it is 100% impermeable and, consequently therewith has an extraordinary electrical insulating capacity. 
     
     
         5 . A method for the manufacture of a cement mortar body, characterized in that: [a] a weight of aggregate ( 4 ) having a rounded surface and a particle size of between 0.1 and 1 mm, and a silica content of 99.5%, is dry mixed with [b] a weight of cement particles ( 5 ) having a particle size of around  5  microns comprised between 27% and 37% of the weight of the total dry mass, to which, [c] without interrupting the mixing operation, there is added a weight of water corresponding to an amount of between 29% and 32% of the weight of cement until a totally homogenous mass is obtained, with perfect hydration of the cement, [d] said mass being poured into a mould and held in said mould for setting thereof with the surface of said mass in contact with a cover that determines the encapsulation of the mould, reduces the evaporation of the water and calibrates one of the dimensions of the body to be obtained. 
     
     
         6 . The method for the manufacture of a cement mortar body of  claim 5 , characterized in that the dry mixing of the solid components of the mortar, in a first stage, and of said components with the addition of water, in a second stage immediately following the first one, is carried out by mixing the components in a mixing point (R) static in space and sequentially, without interrupting said mixing process, on the circulating heterogeneous mixture of said components moving in a closed path that inescapably passes through the static mixing point (R) until a homogenous mixture and the perfect hydration of said cement particles ( 5 ) is obtained. 
     
     
         7 . The method for the manufacture of a cement mortar body of  claim 5 , characterized in that said perfect hydration of the cement gives rise to the formation of a binder for the aggregate ( 4 ) that, known as ettringite ( 6 ), is constituted chemically by tricalcium sulfoaluminate of formula Ca4SO4(AlO3)2 30-32 H2O. 
     
     
         8 . The method for the manufacture of a cement mortar body of  claim 5 , characterized in that the setting of the encapsulated mortar in said forming mould is carried out by a supply of heat of the group comprising exogenous heating, such as by hot air in means of the group comprising furnaces and tunnels, and endogenous heating by high frequency, either taken separately or in the technically possible combinations thereof. 
     
     
         9 . The method for the manufacture of a cement mortar body of  claim 5 , characterized in that the setting of the material is carried out in conditions of a temperature of between 25° and 35° C. and humidity of around 94%. 
     
     
         10 . The method for the manufacture of a cement mortar body of  claim 5 , characterized in that it is optionally possible to incorporate in the possible interstices formed between the aggregate particles ( 4 ), the ettringite binder ( 6 ) and the cement particles ( 5 ), microparticles ( 7 ) of around one micron and colloidal materials, and, in the interstices formed between said aggregate particles ( 4 ), said cement particles ( 5 ) with said ettringite binder ( 6 ) and said microparticles ( 7 ) and said colloidal materials, nanoparticles ( 8 ) and, finally, in the interstices formed between said particles of aggregate ( 4 ) and cement ( 5 ) with the ettringite binder ( 6 ) and said microparticles ( 7 ) and colloidal materials, nanoparticles ( 8 ). 
     
     
         11 . The method for the manufacture of a cement mortar body of  claim 10 , characterized in that part of said nanoparticles ( 8 ) to be used in the process are nanoparticles having tribological properties which when located in the mould and/or the encapsulation and calibrating covers, exert their action in the physical operation of moulding and demoulding, whereas another part of said nanoparticles ( 8 ) consists of nanoparticles acting in the physico-chemical development of the setting of the mortar, providing the finished product with multiple properties determined by the type of nanoparticles ( 8 ) used. 
     
     
         12 . The method for the manufacture of a cement mortar body of  claim 6 , characterized in that the dry mixing of the solid mortar components, in a first stage, and of these with the addition of water, in a second stage immediately following said first stage, is carried out with high frequency vibration, made by means of means of the group comprising mechanical, electrical, electronic, electromagnetic and fluidic means, taken separately or in the technically possible combinations thereof. 
     
     
         13 . The method for the manufacture of a cement mortar body of  claim 6 , characterized in that the dry mixing of the solid mortar components, in a first stage, and of these with the addition of water, in a second stage immediately following said first stage, is carried out with a high vacuum, made by means of means of the group comprising mechanical, electrical, electronic, electromagnetic and fluidic means, taken separately or in the technically possible combinations thereof.